Four-Way Stack-and-Nest Pallet with Full Window-Framed Runners

ABSTRACT

A pallet made according to this invention provides a one-piece plastic pallet with integrated full window-frame runners for improved safety, nesting and stackability. The pallet includes a plurality of recessed portions that form angled leg portions below the lower surface of the deck. The pallet also includes integrated full window-framed runners in order to accommodate four-way entry. Each window-framed runner includes an angled leg portion having about the same draft angle as the opposing sidewall of the recessed portion. The deck also includes a plurality of channels sized to receive a window-framed runner of a second pallet. Each recessed portion also includes a stop to arrest the downward travel of the leg portion of the second pallet and allow for the nested second pallet to be easily removed from the first pallet.

BACKGROUND OF THE INVENTION

This invention relates generally to goods-supporting pallets like thekind transported, raised and lowered by forklift trucks. Morespecifically, the invention relates to goods-supporting pallets that aremade of environmental-friendly plastics and nest one into the other toreduce or minimize storage space.

Goods-supporting pallets made of wood and plastic are well-known in theart. One of the advantages of plastic pallets over wooden pallets isthat plastic pallets can be designed to nest one within the other.However, prior art plastic nesting pallets do not provide a runnerdesign which accommodates 4-way entry of the forklift, nor do theyprovide full window-frame and same-dimensioned runners. Additionally,those plastic nesting pallets are usually one-piece designs which do notincorporate runners of any kind. Plastic pallets that do have runnersare usually assembled from different molded parts and cannot nest.

The pallet disclosed and claimed herein incorporates the best safety,economic and manufacturing features of two distinct types of pallets.Pallets with runners (either wood or plastic) offer fork truck safety,pallet conveyablity, and pallet double-stacking. Pallets without runners(usually only plastic) offer economic outbound and return shipping andmake efficient use of warehouse space. However, there are times when thequalities of both types of pallets are desirable in the same pallet. Theclaimed invention incorporates two critical features of each type ofpallet, full window frame runners for safety and full nesting capacityfor economic shipment, in the same pallet. No other pallet is availablewith these combined critical features.

Because of significant technical challenges, no prior art pallet designincorporates all of the features of the pallet made according to thisinvention. Prior art pallet designs have either compromised on the fullwindow frame runner system, thereby reducing the safety factor, or havelimited the nesting ratio, thereby reducing the economic return of thenesting pallet. To the inventors' knowledge, there is no prior artpallet design that marries both the full window frame and full nestingin the same pallet. A pallet design that accomplishes both is difficultto achieve given that the design has to maintain industry standards tosurvive the rigors and abuse of the fork-truck world yet stillaccommodate an industry load requirement.

SUMMARY OF THE INVENTION

A pallet made according to this invention has a deck that provides agoods-supporting surface along with a plurality of recessed portionsthat form angled leg portions below the lower surface of the deck. In apreferred embodiment, the angle or draft of sidewalls of the recess isabout 4° from vertical. The pallet also includes a first and secondplurality of full window-framed runners, the first plurality ofwindow-framed runners being arranged perpendicular to the secondplurality of window-framed runners in order to accommodate 4-way entryfor a forklift truck. Each window-framed runner shares an angledsidewall of each of the two adjacent recessed portions that it islocated between. The runners are also offset from the peripheral edge ofthe pallet.

The plurality of recessed portions includes a centrally located recessedportion, recessed portions located toward a peripheral edge of thepallet, and recessed portions located at the corners of the pallet. Eachedge or side recessed shares a common centerline with the centralrecessed portion. The goods supporting surface may be a solid surfacehaving a plurality of ribs on its lower surface. The runners may alsoinclude ribs.

To accommodate the floor runner portion of a second pallet and helpprovide an interlocking design, the deck includes a plurality ofchannels. Each channel is located above a floor runner portion of anopposing window-framed runner and sized to receive a window-framedrunner of the second pallet. Each recessed portion also includes a stopto arrest the downward travel of the foot portion of the second palletso that about half the height of the second pallet nests within thefirst pallet.

Objects of the invention are to provide a plastic nesting pallet thathas (1) a one-piece design; (2) full window-frame runners (stringers) toimprove safety during transport and stacking; (3) a runner design thatimproves pallet storage at least about 50%; (4) runners which areoff-set and chamfered to protect the feet; (5) runners with a commondimension; (6) a top deck that incorporates the runners but still allowsthe pallet to nest; (7) a foot design that provides an inter-lockingfootprint but allows for de-stacking; and (8) more static and dynamicload carrying capacity than a similarly sized wooden pallet yet is atleast one-third the weight of that pallet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a preferred embodiment of a pallet madeaccording to this invention.

FIG. 2 is an elevation front view of the pallet of FIG. 1.

FIG. 3 is a cross-section view of the pallet of FIG. 1 taken alongsection line 3-3.

FIG. 4 is an elevation right-side view of the pallet of FIG. 1, theleft-side being a mirror image.

FIG. 5 is a bottom view of the pallet of FIG. 1

FIG. 6 is an isometric view of the pallet of FIG. 1.

FIG. 7 is an isometric bottom view of the pallet of FIG. 1.

FIG. 8 is a cross-section view of the pallet of FIG. 1 as it nestswithin other pallets.

FIG. 9 is a partial bottom view of another preferred embodiment of apallet made according to this invention.

ELEMENTS

The following elements are illustrated in the drawings and referenced inthe Detailed Description of the Preferred Embodiments

10 Stack-and-nest pallet 11 First pallet side 13 Centerline 15 Secondpallet side 17 Centerline 19 Fork entry/window 20 Deck 21 Goodssupporting surface 23 Trapezoidal-shaped portion of 21 25Rectangular-shaped portion of 21 27 Goods supporting surface 29 Goodssupporting surface 30 Open channel 31 Longitudinal side 50 Channel 60Recess 61 Central portion 63 Satellite or petal portion 65 Sidewall 67Top end 120 Lower surface of 20 121 Cross-patterned rib 130 Runner 131Floor runner portion 133 Supporting leg portion 135 Upper end of 133 137Rib 139 Bottom end of 131 141 Lower edge of 137 143 Lower end of 133 145Cross-patterned rib 150 Channel-shaped rib 151 Bottom end 160 Leg orfoot 163 Petal portion 165 Sidewall 169 Bottom end 171 Hole 173 Stop 175Upper end of 173

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A pallet made according to this invention represents a new concept inplastic runner-ed pallets. The pallet (1) blends traditional palletsafety with economic re-use; (2) lowers costs and eliminates assemblybecause of its one-piece design; (3) incorporates geometry that protectsits internal structure; (4) provides integrated full window-framerunners and 4-way entry; (5) lowers handling costs by providing full2-to-1 nesting; (5) is compatible with all conveyor systems; (6) doublestacks with about 8% greater runner surface area (meaning the palletstacks with greater bottom surface area than prior art pallets); (7) isabout 50% lighter than a comparable-sized wood pallet; (8) is 100%recoverable and reusable; (9) has a carbon footprint about 40% smallerthan prior art wood pallets; and (10) accommodates industry loadrequirements. For example, a pallet made according to this inventionthat is made of recycled resin and measures 48 inches long (121.92 cm);40 inches wide (101.6 cm), and 5½ inches (13.97 cm) tall weighs 27pounds (12.25 kg), can be stacked 42 high in a 97-inch (246.38 cm)column, has a dynamic load capacity of 2,400 pounds (1088.62 kg), andhas a static load capacity of 7,500 pounds (3401.94 kg) (not edgerack-able). Because of its improved nesting, 1,260 units can fit withina standard 53-foot (16.15 m) truck making return economically moreattractive.

Referring to the drawings and first to FIGS. 1, 6 & 8, a preferredembodiment of a stack-and-nest pallet 10 made according to thisinvention has a deck 20 that incorporates built-in runners (stringers)130 in a full window frame design but allows a second pallet 10 to nestinside the first pallet 10 up to a 2.5 to 1 ratio. Deck 20 includeschannels 30 and recesses 60 that receive the legs 160 and runners 130 ofthe second pallet 10, respectively. The two pallets 10 preferably nestso that the total height of the nested arrangement is substantially thesame height “X” as a single pallet 10 (see FIG. 8). A pallet 10 madeaccording to this invention is about 33% lighter than a comparably sizedwood pallet while at the same time improving pallet storage by up toabout 60%. In a preferred embodiment, pallet 10 is about 48″ (121.92cm)×40″ (101.6 cm)×5.5″ (13.97 cm), made from environmentally friendlyplastic material, and weighs about 27 pounds (11.34 kg).

Referring now to FIGS. 5-7, each leg 160 conforms to and extends below arespective recess 60, which forms the hollow interior portion of the leg160. The legs 160 and recesses 60 have a unique-interlocking footprint(described below) that is designed to allow for de-stacking the nestedpallets 10. The legs 160 and recesses 60 are one of three types: centerC, corner K, or side S. When viewing pallet 10 from above its deck 20,each recess 60 has a substantially square- or rectangular-shaped centralportion 61 and a set of square- or rectangular-shaped foot or petalportions 63, each petal portion 63 being located at a corner of centralportion 61. Recesses 60 _(C & S) have four petal portions 63 ₍₁₎₋₍₄₎.Recess 60 _(K) has three petal portions 63 _(K(1)-(3)).

The sidewalls 165 of the each leg 160 merge with the sidewalls 65 thatform the recess 60 and extend below the lower surface 120 of deck 20(see FIGS. 3 & 8). Therefore, each leg 160 has a central portion 161 andpetal portions 163 that correspond to those of its complementary recess60. The sidewalls 65, 165 taper at a same draft angle α from the top end67 of recess 60 toward the bottom end 169 of leg 160. In a preferredembodiment, draft angle α is about 4° and sidewalls 165 are about 0.15″(0.38 cm) thick. Bottom end 169 includes a hole 171.

Preferably, one of three different sized rectangular-shaped openchannels 30 lies between adjacent recesses 60 _(C & K); 60 _(C & S); and60 _(K & S) (see also FIG. 1). Channel 30 _(N) is the narrowest channel30 and runs parallel to pallet side 11 (which is preferably the shorterside of pallet 10), between the center recess 60 _(C) and a cornerrecess 60 _(K). Channel 30 _(W), which is the widest channel 30, alsoruns parallel to pallet side 11 but between center recess 60 _(C) and aside recess 60 _(S). Channel 30 _(M)—whose width lies between that ofchannels 30 _(N & W)—runs substantially parallel to pallet side 15 (thelonger side of pallet 10), between a corner recess 60 _(K) and a siderecess 160 _(S).

A runner 130 lies substantially directly below each channel 30. Eachrunner 130 is a full window frame runner and provides a fork entry 19(making pallet 10 a full four-way entry pallet). Runner 130 is chamferedand includes a floor runner portion 131 and a supporting leg portion133. The leg portion 133 is off-set relative to the floor runner portion131 and extends away from an opposing leg 160 at a draft angle β. In apreferred embodiment, draft angle β is about 4°, substantially equal tothat of draft angle α.

Similar to channels 30, each floor runner portion 131 is one of threedifferent widths, with floor runner 131 _(W) corresponding to, lyingbeneath, and having a slightly smaller width than channel 30 _(W) sothat the runner 130 _(W) of one pallet 10 may be received by acorresponding channel 30 _(W) of a second pallet 10. Floor runnerportion 131 _(N) corresponds to, lies beneath, and has a slightlysmaller width than channel 30 _(N). Floor runner portion 131 _(M)corresponds to, lies beneath, and has a slightly smaller width thanchannel 30 _(M). In a preferred embodiment, floor runner 131 _(N) isabout 1.4″ wide (3.55 cm), 131 _(M) is about 1.9″ (4.83 cm) wide, and131 _(W) is about 2.9″ (7.37 cm) wide. The leg portion 133 at wider atits upper end 135 than at its lower end 145 (which merges into floorrunner portion 131).

The bottom end 139 of the floor runner portion 131 lies substantially inthe same horizontal plane as the bottom end 169 of the legs 160.Extending between the upper end 135 of the leg portion 133 are ribs 137.Each rib 137 lies substantially directly below a longitudinal edge 31 ofa corresponding channel 30. The rib 137 runs the length of the channel30 and extends downward and beyond the lower surface 120 of deck 20.

Deck surface 20 may include a channel 50 that corresponds to achannel-shaped rib 150 (see FIGS. 1 & 5). Channel 50 runs diagonallybetween and in communication with opposing petal portions 63 of thecenter recess/leg 60 _(C)/160 _(C), and an adjacent corner recess/leg 60_(K)/160 _(K). The rib 150 extends past the lower surface 120 of deck 20with its bottom end 151 lying substantially in the same horizontal planeas the lower edge 141 of the rib 137. FIG. 9 illustrates an alternatepreferred embodiment of pallet 10. Channel 50 and its corresponding rib150 have been eliminated in favor of a cross-patterned rib design 121 onthe lower surface 120 of deck 20. Cross-patterned ribs 145 have alsobeen added to the floor runner portion 131.

The arrangement of open channels 30, channels 50, and recesses 60 definedifferent goods supporting surface portions of deck 20. Referring toFIG. 6 and dividing pallet 10 into four quadrants I-IV as defined bycenterlines 13 & 17, and using quadrant I as an example, two goodssupporting surfaces 21A & B lie opposite one another and adjacent tochannel 50. Each surface 21 is made up of a trapezoidal-shaped portion23 and a rectangular-shaped portion 25. Trapezoidal-shaped portions 23A& B are located between channels 30 _(M) and 50. Rectangular-shapedportions 25A & B are located adjacent channels 30 _(W) and 30 _(M),respectively. Another goods supporting surface 27A & B lies betweenchannel 30 _(M) and pallet side 15 and between channel 30 _(N) and side11, respectively. Goods supporting surface 29 lies between the channels30 and recesses 60.

Referring to FIGS. 2-4 & 8 (see also FIG. 9), the bottom end 169 of eachleg 160 rests on a floor surface or, when nesting on a second pallet 10,on the respective upper end 175 of a set of stops 173 located withineach recess 60 of the second pallet 10 (see also FIG. 1). The bottom end139 of each runner 130 rests on the floor surface or, when nesting on asecond pallet, is received by the open channel 30 of the second pallet.Therefore, when pallets 10 are nested, each recess 60 of the lowerpallet 10 receives a portion of the complementary leg 160 of the upperpallet 10 and each channel 30 of the lower pallet 10 receives a runner130 of the upper pallet 10. The stops 73 are preferably dimensioned sothat when the upper pallet 10 is nesting within the lower pallet 10, theportion of the upper pallet 10 residing within the lower pallet 10 isabout one-half the total height of each pallet 10 or “X/2” and theclearance between the leg 160 and its receiving recess 60 is about 0.05″(0.127 cm).

A pallet made according to this invention blends concepts, materials,features without compromise to meet the objectives previously stated.Further, it accomplishes the objectives in a one-piece design. Almostall other prior art runner-ed plastic pallets require two (or more)parts that are post-forming assembled. The inventors' pallet has beendesigned and engineered for production on a simple straight pull mold(without cams) that lowers production time and dollars. One criticaltechnical issue was pallet runner survival when stacks of pallets (e.g.40 pallets stacked one on top of the other) are moved at one time. Therunner has been reinforced to withstand that function, something mostsimilar pallets have not done.

While preferred embodiments of a stack-and-nest pallet have beendescribed with a certain degree of particularity, modifications can bemade in the details of construction without departing from the scope ofthe patent claims below.

1. A pallet comprising: a deck including a goods-supporting surface anda plurality of recessed portions, each recessed portion having angledsidewalls that form a leg portion below a lower surface of the deck; afirst and second plurality of full window-framed runners, the firstplurality of full window-framed runners arranged perpendicular to thesecond plurality of full window-framed runners, each full window-framedrunner being offset from a peripheral edge of the deck surface andlocated between two adjacent recessed portions; a runner leg portion ofeach full window-framed runner angling away from an opposing angledsidewall of an adjacent recessed portion, the runner leg portion and theopposing angled sidewall having a substantially same draft anglerelative to vertical.
 2. A pallet according to claim 1 furthercomprising the pallet being a one-piece design pallet.
 3. A palletaccording to claim 2 further comprising the pallet being a moldedpallet.
 4. A pallet according to claim 3 further comprising the moldedpallet being a straight pull mold injection pallet.
 5. A palletaccording to claim 1 further comprising the plurality of recessedportions including a central recessed portion, a corner recessedportion, and a side recessed portion.
 6. A pallet according to claim 1further comprising the deck including a plurality of channels, eachchannel located above a floor runner portion of a full window-framedrunner and sized to receive a full window-framed runner of a secondpallet.
 7. A pallet according to claim 1 further comprising eachrecessed portion including a stop, the stop arresting the downwardtravel of a second pallet being nested within the first-mentionedpallet.
 8. A pallet according to claim 7 further comprising a height ofthe stop being no greater than one-half the depth of the recessedportion.
 9. A pallet made according to claim 7 further comprising aclearance between the leg portion of the second pallet and a recessedportion of the first-mentioned pallet receiving the leg portion of thesecond pallet being no greater than about 0.05 inches (0.13 cm) when thesecond pallet is nesting in the first-mentioned pallet.
 9. A palletaccording to claim 1 further comprising the substantially same draftangle being about 4 degrees.